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Avoid the risks of not having a proper air control system in place

Avoid the risks of not having a proper air control system in place

With the number of products that require processing, separation, and conveying through plants and factories, air control systems provide us a unique solution for a multitude of goods and materials. Some of the most common products that utilize pneumatic conveying and industrial air systems include food, milling, oil seed, wood, plastics, and hemp, just to name a few.

Typically, these systems need to be designed and engineered from scratch in order to ensure the control system design meets the logistical challenges of the plant/warehouse, is able to operate with little to no human oversight, and effectively moves materials along its predetermined route. Most importantly, air control systems need to be safe to operate and yield a final product with minimal fines, flaws, and contaminates.

The risks of not having a proper air control system in place can lead to a multitude of issues that can result in system malfunction, risk to the workplace/workforce, and flaws in the final product. Here are the top risks you may fall victim to by not having the proper air control system in place for your application.


As with any mechanical operation, there’s always a risk of malfunction or mechanical issue. This can either be due to the industrial air system being faulty in design, construction, or how it’s being utilized. Some common issues that can arise with an improper air control system include:

  • Pressure of the air control system either being too high or too low
  • Air seal leaks in the pneumatic conveying system
  • Damaged or dirty filters
  • Control valve issues
  • Slow moving actuator

Any of these issues can compromise an industrial air system, which can lead to unplanned work stoppages, flawed or damaged product, and lost hours while dealing with repairs and troubleshooting. The best way to circumvent this issue is by going with a company that has an established history of success designing and constructing air control systems.


Another big risk of having the incorrect air control system in place is compromising the product. Pneumatic conveying is a delicate process that requires absolute precision. If your air control system isn’t producing the correct amount of airflow in respect to a product’s terminal velocity, this can lead to unwanted particulate matter and fines being included in the final product. For instance, in the case of cereal or pet food, there could be a large amount of dust that gets included in the final product if the wrong air control system is in place.


Although dust explosions are few and far between, they are always a risk that factory and warehouse workers need to be aware of when working with products that produce combustible dust. Facilities that create dust particles that are airborne are always one of the top concerns when it comes to National Fire Protection Association (NFPA) and Occupational Safety & Health Administration (OSHA) protocols. Not only can a dust explosion seriously damage equipment, compromise products, and cause work stoppages, it can also be dangerous to your workforce. Dust characteristics must be carefully considered during filter selection and air control system design. This is yet another reason why it makes financial sense to go with a company that has a large amount of experience to pull from such as Kice. We can proactively ensure that the risk combustible dust poses is mitigated.


As we’ve detailed here, there are numerous risks you take on by not having the proper air control system in place in your warehouse or factory. When it comes to pneumatic conveying and industrial air systems, you always want to go with a company that has a wide breadth of experience in designing, engineering, and constructing pneumatic solutions for a wide variety of materials. This keeps your operation moving, your employees safe, and your product quality high.

If you’re interested in having an air control system designed for your company’s operation, the first step is to get in touch with our team so that we can analyze your product. Once we’ve done that, we can provide some recommendations as to which industrial air system is the appropriate fit for your factory or warehouse.

You can either contact us by phone at (316) 744-7151 or email us at